Volkswagen Workshop Service and Repair Manuals

Removing and installing intake manifold flap motor -V157- and intake manifold flap potentiometer -G336- Special tools and workshop equipment required

t  Assembly tool -T10118-

t  Commercially available 1/4" drive ratchet handle e.g.. Hazet 2264 t  T30 bit insert Removing –  Remove engine cover/air filter → Chapter.

–  Unscrew air duct on lock carrier.

–  Remove turbocharger air recirculation valve -N249--1- with housing and hose → Chapter.

–  Pull off vacuum lines -arrows-. –  Pull off following connectors:   Note Use assembly tool -T10118- to facilitate opening of connectors which are less accessible t  Connector for intake manifold flap motor -V157- t  Connector for activated charcoal filter system solenoid valve 1 -N80- t  Connector for intake manifold pressure sender -G71-. t  Connector for throttle valve module -J338- t  Connector for fuel pressure sender for low pressure -G410-

–  Disconnect additional electrical connectors -arrows-. –  Loosen cable retainer -A- and place complete wiring harness to side.

–  Remove brackets for connectors from coolant pipe -arrows-.   Note t  Only loosen the nut with the left arrow until the retainer can be moved to the side. t  Plastic brackets are clipped on. t  For clarity, the illustration shows the intake manifold removed from the engine.

–  Prise coupling rod -arrow- off intake manifold flap motor -V157-. –  Unscrew bolts -1- and -2- using 1/4" drive ratchet handle and T30 bit insert.   Note

The rear bolt -arrow - can only be unscrewed with a ratchet handle. The space between the bolt and the water pipe is very constricted. –  Remove intake manifold flap motor -V157- from intake manifold. Installing Install in reverse order. In the process, note the following:

–  Insert bolts -1 and 2- by hand to prevent damage to the thread. –  Install turbocharger air recirculation valve -N249- → Chapter. If the intake manifold flap motor -V157- or the intake manifold were renewed, the intake manifold flap potentiometer -G336- must be adapted to the engine control unit → Vehicle diagnostic tester„guided functions“.